Method for carbon-catalysed thiosulfate leaching of gold-bearing materials

ABSTRACT

The present disclosure is directed to a gold recovery process in which activated carbon or another carbon-based material is used to accelerate thiosulfate leaching of gold from a gold-bearing material.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application claims the benefits of U.S. Provisional Application Ser. Nos. 62/794,887, filed Jan. 21, 2019, and 62/819,005, filed Mar. 15, 2019, both entitled “METHOD FOR THIOSULFATE LEACHING OF GOLD-BEARING MATERIALS”, and both of which are incorporated herein by this reference in their entireties.

FIELD

The invention relates generally to leaching of metal-containing materials and particularly to thiosulfate leaching of precious metal-bearing materials.

BACKGROUND

The conventional cyanidation/carbon in pulp process has been the main gold extraction method for decades. The lixiviant most commonly used in gold leaching is cyanide. Cyanide possesses a relatively low cost, its chemistry is simple and well known, and forms strong complexes with gold that are stable in aqueous solutions. While cyanidation is effective for leaching gold from some carbonaceous or complex ores, there are serious environmental concerns associated with the use of cyanide in gold leaching processes and for certain gold ores, such as carbonaceous ores, cyanide can have high reagent consumption.

Thiosulfate is among the more successful alternative lixiviants for effective leaching of gold. An example of a thiosulfate leaching process for precious metal-bearing materials is shown in U.S. Pat. No. 7,544,232. The ammonia-thiosulfate system commonly uses cupric ions as oxidant. This is because the low solubility of oxygen and its slow reduction rates on gold surfaces result in slow dissolution rates. While cupric ions are a better oxidant for gold than oxygen, oxygen is still required to regenerate the oxidant; unfortunately, the combination of oxygen and copper in the ammonia-thiosulfate system has been reported to increase the degradation rate of thiosulfate to produce tetrathionate and other polythionates. Ammonia-free thiosulfate systems can be more attractive from an environmental point of view.

Due to the need for an environmentally acceptable replacement to cyanide in gold leaching, significant work has been done on how to improve thiosulfate leach kinetics. Thiosulfate leach experiments at temperatures and oxygen overpressures ranging 40-80° C. and 10-100 psi, respectively, have found that gold recovery was affected by temperature and thiosulfate concentration but was less sensitive to the oxygen overpressure. Increases in temperature, and Cu(II) and dissolved oxygen concentrations have been found to have a positive effect on the dissolution rate of gold. The rate of gold dissolution can be increased in the presence of sulfide minerals due to galvanic interactions where the reduction rate of oxygen was faster on the surface of sulfide minerals than on the surface of gold. Finally, U.S. Pat. No. 10,161,016 teaches a process to pretreat thiosulfate-refractory oxide ores using activated carbon. In the pretreatment process, the ore slurry is contacted with activated carbon in the presence of oxygen prior to the thiosulfate leach. The pretreatment process was found to increase gold recovery from 23-26% to 71-86%.

Unfortunately, the performance of thiosulfate in the leaching of gold can be very ore sensitive. Some oxide ores may be refractory in nature. They neither yield sufficient gold leaching in a thiosulfate leach system nor are leached as effectively compared to cyanide. Thiosulfate gold extraction from some oxide ores can be minimal. As oxide ores do not contain sulfides (or have very low levels of sulfide), the refractory nature cannot be mitigated in the same manner as for sulfide ores (e.g., by roasting, bio-oxidation or pressure oxidation).

There is a need for a thiosulfate leaching method to address the refractory nature of certain oxide ores in the thiosulfate leach system.

SUMMARY

These and other needs are addressed by the various embodiments and configurations of the present invention. The disclosure is directed generally to leaching precious metal-bearing materials with thiosulfate in the presence of carbon.

In some embodiments, the leaching process can include the steps:

(a) providing a particulate carbon-based material comprising one or more of activated carbon, activated charcoal, coke, hard carbon derived from at least one of coconut shells and elemental carbon, a calcined resin, and mixtures thereof;

(b) providing a precious metal-bearing material having a first precious metal thiosulfate leaching value in the absence of contact with the particulate carbon-based material;

(c) contacting the precious metal-bearing material with the particulate carbon-based material, thiosulfate, an anion exchange resin, and an oxidant to form a slurry; and

(d) leaching a precious metal from the slurried precious metal-bearing material, wherein the anion exchange resin has a greater affinity for the leached precious metal than the particulate carbon-based material and wherein the slurried precious metal-bearing material has a second precious metal thiosulfate leaching value that is more than the first precious metal thiosulfate leaching value.

In some embodiments, the leaching process can include the steps:

a) contacting a gold-bearing material with a carbon-based material and one or more of a thiosulfate lixiviant and an anion exchange resin to form a slurry, the carbon-based material comprising one or more of activated carbon, activated charcoal, coke, hard carbon derived from at least one of coconut shells and elemental carbon, a calcined resin, and mixtures thereof;

b) thereafter contacting the slurry with an oxidant to leach gold from the gold-bearing material and deposit the leached gold onto the anion exchange resin; and

c) contacting the gold-containing anion exchange resin with an eluant to from a gold-containing eluant and a barren ion exchange resin for recycle to step (a).

In some embodiments, the leaching process can include the steps:

a) contacting a precious metal-bearing material with a particulate carbon-based material, thiosulfate, and an anion exchange resin to form a slurry, wherein the precious metal-bearing material having a first precious metal thiosulfate leaching value in the absence of contact with the particulate carbon-based material and wherein the particulate carbon-based material comprising one or more of activated carbon, activated charcoal, coke, hard carbon derived from at least one of coconut shells and elemental carbon, a calcined resin, and mixtures thereof; and

b) contacting the slurry with an oxidant to leach a precious metal from the slurried precious metal-bearing material, wherein the anion exchange resin has a greater affinity for the leached precious metal than the particulate carbon-based material and wherein the slurried precious metal-bearing material has a second precious metal thiosulfate leaching value that is more than the first precious metal thiosulfate leaching value.

The precious metal, for example, can be gold.

Leaching can be performed in the presence of molecular oxygen but in the absence or substantial absence of a surrogate oxidant, such as copper.

The addition of a carbon-based material, such as fine activated carbon, can result in increased dissolution rates and gold recoveries. While not wishing to be bound by any theory, it is believed that the carbon-based material and the precious metal, such as gold, form galvanic couples and that the rate of oxygen reduction is increased due to the increased surface area available on finely sized carbon-based material. In particular, the use of activated carbon as a catalyst in the thiosulfate leach of gold is a process alternative that may not require the addition of surrogate oxidants (like copper), can work at temperatures as low as 30° C., and can have low thiosulfate degradation, making it an attractive alternative for the leaching of gold.

Whether or not carbon is removed after leaching depends on the particle size of the carbon employed. When coarse carbon is employed, the carbon is typically removed. When fine carbon is employed, the carbon is typically not removed.

Finely sized carbon can be contacted with the precious metal-bearing material either separately after grinding of the material or before and/or during grinding. In the latter case, the carbon particles can be coarsely sized but are ground to a fine size distribution similar to a size distribution of the ground precious metal-bearing material.

Prior to leaching, the slurried precious metal-bearing material can be substantially free of contact with the oxidant.

The various slurry components can be added in any order. In some applications, the anion exchange resin and/or thiosulfate lixiviant is contacted with the precious metal-bearting material before the carbon-based material.

The precious metal-bearing material can be amenable to cyanide leaching (and therefore is not cyanide refractory) but not to thiosulfate leaching (i.e., the material is a thiosulfate refractory precious metal-bearing material). In other words, leaching of precious metals from the precious metal-bearing material by cyanide can be more effective than precious metal leaching by thiosulfate. Even when leaching of the precious metal-bearing material has similar precious metal recoveries using either cyanide or thiosulfate as the lixiviant, the leaching process of this disclosure can enhance further precious metal recovery by thiosulfate. The precious metal-bearing material may or may not be concentrated. Generally, the precious metal is in a matrix that is predominantly one or more oxides. By way of example, the precious metal-bearing material can contain more oxides than sulfides.

The gold recovery process can be carried out under ambient conditions (room temperature and atmospheric pressure) in less than 24 hours. Increasing the process temperature can further improve the gold recovery and/or pretreatment kinetics.

The carbon-based material can be removed from the pre-treated slurry by screening, which generally requires about 95% or more, and even more commonly about 98% or more of the carbon to be retained on the screen while about 90% or more and more commonly about 95% or more of the precious metal-bearing material passes through the screen. The relative mean, median, mode, and P₈₀ particle sizes of the carbon and precious metal-bearing material are selected to produce at least these levels of separation.

After carbon separation, the leached slurry can be discharged in tailings and the recovered carbon-based material recycled to the leaching step.

The present disclosure can provide a number of advantages depending on the particular configuration. Thiosulfate leaching oxide ores in oxygenated water in the presence of activated carbon or other carbon-based materials can improve significantly the gold recovery otherwise realized by thiosulfate leaching. The process can have a low operating cost and provide a straightforward method to thiosulfate leach gold from oxides. Attrition, due to mixing of the slurry, is commonly the only cause for carbon loss and may be minimized by proper engineering of the agitators and reactors. The carbon-based material can be recycled and re-used, thereby decreasing operating costs. Inexpensive air (or more expensive oxygen gas) are the only reagents consumed, thereby making the economics of the process very attractive.

These and other advantages will be apparent from the disclosure of the aspects, embodiments, and configurations contained herein.

As used herein, “at least one”, “one or more”, and “and/or” are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B and C”, “at least one of A, B, or C”, “one or more of A, B, and C”, “one or more of A, B, or C”, “A, B, and/or C”, and “A, B, or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together. When each one of A, B, and C in the above expressions refers to an element, such as X, Y, and Z, or class of elements, such as X₁-X_(n), Y₁-Y_(m), and Z₁-Z_(o), the phrase is intended to refer to a single element selected from X, Y, and Z, a combination of elements selected from the same class (e.g., X₁ and X₂) as well as a combination of elements selected from two or more classes (e.g., Y₁ and Z_(o)).

It is to be noted that the term “a” or “an” entity refers to one or more of that entity. As such, the terms “a” (or “an”), “one or more” and “at least one” can be used interchangeably herein. It is also to be noted that the terms “comprising”, “including”, and “having” can be used interchangeably.

The term “activated carbon” is a form of carbon processed to be riddled with small, low-volume pores that increase the surface area available for adsorption or chemical reactions. Activated carbon can be granular, extruded, bead, impregnated, and/or polymer coated.

The term “carbon” includes a carbon-containing organic material, such as one or more of activated carbon (or activated charcoal or activated coal), coal (e.g., peat, lignite, sub-bituminous coal, bituminous coal, steam coal, anthracite, and graphite), brown coal, coke, hard carbon derived from coconut shells or elemental carbon, a calcined resin, and mixtures thereof.

The term “means” as used herein shall be given its broadest possible interpretation in accordance with 35 U.S.C., Section 112(f) and/or Section 112, Paragraph 6. Accordingly, a claim incorporating the term “means” shall cover all structures, materials, or acts set forth herein, and all of the equivalents thereof. Further, the structures, materials or acts and the equivalents thereof shall include all those described in the summary of the disclosure, brief description of the drawings, detailed description, abstract, and claims themselves.

The term “precious metal” refers to gold and silver.

A “thiosulfate refractory” precious metal-bearing material is a material in which at least part of the precious metal-bearing material is naturally resistant to recovery by thiosulfate leaching.

Unless otherwise noted, all component or composition levels are in reference to the active portion of that component or composition and are exclusive of impurities, for example, residual solvents or by-products, which may be present in commercially available sources of such components or compositions.

All percentages and ratios are calculated by total composition weight, unless indicated otherwise.

It should be understood that every maximum numerical limitation given throughout this disclosure is deemed to include each and every lower numerical limitation as an alternative, as if such lower numerical limitations were expressly written herein. Every minimum numerical limitation given throughout this disclosure is deemed to include each and every higher numerical limitation as an alternative, as if such higher numerical limitations were expressly written herein. Every numerical range given throughout this disclosure is deemed to include each and every narrower numerical range that falls within such broader numerical range, as if such narrower numerical ranges were all expressly written herein. By way of example, the phrase from about 2 to about 4 includes the whole number and/or integer ranges from about 2 to about 3, from about 3 to about 4 and each possible range based on real (e.g., irrational and/or rational) numbers, such as from about 2.1 to about 4.9, from about 2.1 to about 3.4, and so on.

The preceding is a simplified summary of the invention to provide an understanding of some aspects of the invention. This summary is neither an extensive nor exhaustive overview of the invention and its various embodiments. It is intended neither to identify key or critical elements of the invention nor to delineate the scope of the invention but to present selected concepts of the invention in a simplified form as an introduction to the more detailed description presented below. As will be appreciated, other embodiments of the invention are possible utilizing, alone or in combination, one or more of the features set forth above or described in detail below.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawing is incorporated into and forms a part of the specification to illustrate several examples of the present disclosure. This drawing, together with the description, explains the principles of the disclosure. The drawing simply illustrates preferred and alternative examples of how the disclosure can be made and used and is not to be construed as limiting the disclosure to only the illustrated and described examples. Further features and advantages will become apparent from the following, more detailed, description of the various aspects, embodiments, and configurations of the disclosure, as illustrated by the drawings referenced below.

FIG. 1 is a process flow schematic according to an embodiment of the disclosure;

FIG. 2 is a plot of gold recovery (vertical axis) against time (horizontal axis) and illustrates the effect of carbon pretreatment on gold recovery from sample S1 by CaTS-RIL;

FIG. 3 is a plot of gold recovery (vertical axis) against time (horizontal axis) and illustrates the effect of carbon pretreatment and fine carbon on thiosulfate leach recovery from sample S1;

FIG. 4 is a plot of gold recovery (vertical axis) against time (horizontal axis) and illustrates the effect of fine carbon on gold recovery from the carbon flotation tails;

FIG. 5 is a plot of gold recovery (vertical axis) against time (horizontal axis) and illustrates the effect of fine carbon on gold recovery by thiosulfate from sample S-3;

FIG. 6 is a plot of gold recovery (vertical axis) against time (horizontal axis) and illustrates the effect of carbon pretreatment on gold recovery from sample S1;

FIG. 7 is a plot of gold recovery (vertical axis) against time (horizontal axis) and illustrates the effect of fine carbon on gold recovery from the carbon flotation tails;

FIG. 8 depicts the galvanic interactions between gold and carbon;

FIG. 9 is a plot of gold recovery (vertical axis) against carbon concentration (horizontal axis) and illustrates the effect of activated carbon on gold recovery by thiosulfate;

FIG. 10 is a plot of gold recovery (vertical axis) against time (horizontal axis) and illustrates the effect of copper, resin and temperature on the carbon-assisted (10 kg/g) thiosulfate leaching of gold from S1;

FIG. 11 is a plot of gold recovery (vertical axis) against time (horizontal axis) and illustrates the effect of thiosulfate concentration on gold recovery from sample S2 in the presence and absence of 10 g/kg carbon;

FIG. 12 is a plot of gold recovery (vertical axis) against time (horizontal axis) and illustrates the effect of coarse activated carbon on gold recovery by thiosulfate leaching;

FIG. 13 is a plot of gold recovery (vertical axis) against time (horizontal axis) and illustrates the effect of carbon-solids contact on thiosulfate gold leaching; and

FIG. 14 is a plot of gold recovery (vertical axis) against time (horizontal axis) and illustrates the effect of fine activated carbon on the thiosulfate leach of gold from sample S2.

DETAILED DESCRIPTION Overview

The present disclosure provides a process for leaching precious metal-bearing materials. The process can be performed prior to or during thiosulfate leaching and improve the overall precious metal recovery of thiosulfate refractory precious metal-bearing materials. Leaching is done by substantially simultaneously mixing a slurry containing the precious metal-bearing material, water, thiosulfate, a carbon-based material, and dissolved molecular oxygen (as the oxidizing reagent) and performing leaching in the presence of the various components for a predetermined residence time. The carbon-based material is maintained in the slurry during leaching to provide increased gold recoveries compared to the prior art.

In some applications, the thiosulfate lixiviant is contacted with the slurried precious metal-bearing material before the carbon-based material. Typically, at least about 50 mole %, more typically at least about 75 mole %, and even more typically at least about 95 mole % of the thiosulfate lixiviant contacted with the slurried precious metal-bearing material before any or most of the carbon-based material is added to the slurry. Stated differently, the slurried precious metal-bearing material typically contains more than about 0.001, more typically more than about 0.0025, and more typically more than about 0.005 molar thiosulfate before contact with any or most of the carbon-based material.

In some applications, a precious metal ion exchange resin is contacted with the slurried precious metal-bearing material before the carbon-based material. Typically, at least about 50 wt. %, more typically at least about 75 wt. %, and even more typically at least about 95 wt. % of the ion exchange resin contacted with the slurried precious metal-bearing material before any or most of the carbon-based material is added to the slurry.

Surprisingly and unexpectedly, the amount of carbon-based material required to realize a relatively high gold recovery (e.g., of at least about 80%, more typically of at least about 85%, more typically of at least about 90%, and more typically of at least about 95%) is relatively low compared to the pretreatment process of U.S. Pat. No. 10,161,016. While not wishing to be bound by any theory, it is believed that the carbon-based material and precious metal form a galvanic couple and that oxygen reduction rate is increased due to the increased surface available on the carbon-based material. The use of activated carbon, in particular, as a catalyst in the thiosulfate leach of the precious metal may not require the addition of surrogate oxidants (like copper) and that can work at lower temperatures, making the process more attractive for leaching gold when cyanide use is not an option. The reduced carbon requirements enable the carbon-based material to be discarded with the tailings without substantially reducing the economic viability of the process.

The precious metal-bearing material can be an oxide ore, concentrate, tailings, leach residue, calcine, and other precious metal-bearing oxide materials. Typical precious metal-bearing oxide ores and concentrates may contain silicates, phosphates, iron oxides, and hydroxides, and relatively low levels of residual sulfides.

The optimum solution thiosulfate concentration to maintain during leaching and therefore the optimum solution thiosulfate concentration in the thiosulfate lixiviant will depend on the nature of the material being leached, but will typically range from about 0.005 to about 2 molar (M), more typically about 0.02 to about 0.5 M, and even more typically from about 0.05 to about 0.2 M. The source of the fresh thiosulfate 148 can be any available thiosulfate-containing compound, such as sodium thiosulfate, potassium thiosulfate, calcium thiosulfate, ammonium thiosulfate, or any other thiosulfate containing material or thiosulfate precursor. In some embodiments, the thiosulfate lixiviant is substantially free of ammonia, with no more than about 25%, more typically no more than about 10%, and even more typically no more than about 5% of the thiosulfate being compounded with ammonia.

While leaching may be performed at atmospheric, sub-atmospheric or super-atmospheric pressure and across a wide range of slurry temperatures, the catalytic effect of the carbon-based material surprisingly enables leaching to occur rapidly at temperatures as low as 30 degrees Celsius.

An embodiment of a leaching process will be discussed with reference to FIG. 1.

In a typical implementation of the leaching process, the precious metal-bearing material 100 is mixed, in a stirred tank, vat, or other suitable reactor, with an oxidant 108, thiosulfate lixiviant 110, and the carbon-based material 118, such as activated carbon, thiosulfate, and water 104 to form the leaching slurry 116. The oxidant 108, commonly molecular oxygen, is typically contacted by sparging the slurry. The molecular oxygen can be supplied by a suitable source, such as air, oxygen-enriched air, or industrially-pure oxygen, with ambient air being preferred. The process can be carried out in any water source, whether raw water or relatively clean process water. Other suitable reactors, such as pulse columns, can be any reactor able to adequately mix carbon, the slurried precious metal-bearing material, and gas.

It has been surprisingly and unexpectedly discovered, however, that relatively high leaching kinetics can be realized without a pre-treatment step as disclosed in U.S. Pat. No. 10,161,016. A typical implementation of the leaching process of FIG. 1 therefore excludes (or is performed in the absence of) a pre-treatment step. Commonly, the various components, namely the precious metal-bearing material 100, water 104, thiosulfate lixiviant 110, and carbon-based material 118 are added substantially simultaneously (e.g., before the commencement of precious metal leaching or before contact of the slurry with a precious metal ion-exchange resin in a resin-in-leach or resin-in-pulp leaching process, before solvent extraction in a solvent extraction leaching process). In some implementations, the various components are added before addition of the oxidant 108, though the oxidant 108 can in other implementations be added substantially simultaneously with the other components. In some implementations, the precious metal-bearing material 100, water 104, and carbon-based material 118 are combined before, during, or immediately after comminution but before oxidant 108 addition. Thiosulfate lixiviant 110 may or may not be added before or during comminution.

Referring again to FIG. 1, the thiosulfate lixiviant 110 in the reactor leaches one or more precious metals from the precious metal-bearing material 100. Due to presence of the carbon-based material 118 during leaching, other surrogate oxidants 108 (besides molecular oxygen) are not typically required during precious metal recovery 120.

The absence or substantial absence of (added and/or total) copper in the leach during precious metal recovery 120 can greatly simplify the process. Elimination or near-elimination of (added and/or total) copper from the leach during precious metal recovery 120 can provide the advantage of allowing for a consistently high and reproducible precious metal extraction over a broader pH range than was previously possible with the other thiosulfate leaching processes. Oxidative degradation of thiosulfate to polythionates and sulfates is accelerated markedly in the presence of copper ions. The oxidative degradation reactions are slowed considerably at elevated oxygen partial pressure in the absence or near-absence of copper. Typically, the (added and/or total solution) copper concentration is no more than about 20 ppm, more typically no more than about 15 ppm, more typically no more than about 10 ppm, more typically no more than about 5 ppm, and even more typically no more than about 2.5 ppm. In this process, leaching can be operated at about pH 7-12, typically about pH 8-11, more typically about pH 8-10, and even more typically at a pH less than pH 9. The oxidation-reduction potential (ORP) during precious metal recovery 120 typically ranges from about 100 to about 350 mV and more typically from about 150 to about 300 mV (vs. the standard hydrogen electrode (SHE)).

The weight ratio of the carbon-based material 116 (either added or total (including both added and natively occurring carbon-based material in the precious metal-bearing material) to the precious metal-bearing material 100 during precious metal recovery 120 can vary depending on the requirements of the specific ore, the properties of the carbon-based material itself, and the desired level of precious metal recovery. In some applications, for coarsely sized carbon-based material 118 the weight ratio of the precious metal-bearing material 100 to the carbon-based material 118 is typically more than about 50:1, more than about 100:1, more typically at least about 125:1, more typically at least about 150:1, more typically at least about 175:1, and more typically at least about 200:1. In some applications, the weight ratio of the precious metal-bearing material 100 to the carbon-based material 118 is no more than about 1,000:1, more typically no more than about 850:1, more typically no more than about 750:1, more typically no more than about 650:1, and more typically no more than about 500:1. In other applications, lower weight ratios of the precious metal-bearing material 100 to the carbon-based material 118 are employed.

In some embodiments, the precious metal-bearing material is substantially free of organic carbon. Stated differently, the precious metal-bearing material typically comprises no more than about 1 wt. %, more typically comprises no more than about 0.5 wt. %, more typically comprises no more than about 0.25 wt. %, more typically comprises no more than about 0.1 wt. %, more typically comprises no more than about 0.05 wt. %, and even more typically comprises no more than about 0.01 wt. %, organic carbon.

The finely sized carbon particles in the carbon-based material 118 are generally not separated from the particles of the leached barren precious metal-bearing material 100. After precious metal recovery, the finely sized carbon particles are typically sent to tailings or waste along with the leached precious metal barren material 100. However, as shown by optional step 140, the carbon particles can be separated from the leached precious metal barren material, such as by screening (for carbon particles coarser than the leached precious metal barren material) or flotation, and discarded separately or recycled to the leaching slurry 116.

The finely sized carbon particles in the carbon-based material 118 can be formed by adding coarse carbon into the grinding stage to grind the precious metal-bearing feed material and carbon together to form a combined precious metal-bearing and carbon-containing feed to the mixing stage. The fully comminuted material particle size of the carbon-based material 118 and precious metal-bearing material 100 is typically at least smaller than 80% passing about 48 mesh (300 microns), more typically 80% passing about 100 mesh (150 microns), and most typically 80% passing about 200 mesh (75 microns).

Leaching during precious metal recovery 120 is typically done by resin-in-pulp (“RIP”) treatment. Resin-in-pulp treatment can be performed in any suitable vessel. A preferred vessel is a Pachuca tank, which is an air-agitated, conical bottomed vessel, with air being injected at the bottom of the cone. An advantage of the Pachuca system is reduced resin bead breakage and improved dispersion of the resin beads in the slurry as compared to mechanically agitated systems. The RIP recovery is preferably carried out in four or more tanks connected in series, more preferably between four and eight such Pachuca tanks.

The ion exchange resin should have a higher affinity for the selected precious metal to be recovered (e.g., gold or silver) than the carbon-based material. Accordingly, strong-base anion (SBA) exchange resins are commonly employed, through certain medium-base resins may also be employed. These resins generally contain quaternary ammonium functional groups with fixed positive charges. A commercial example of a strong-base ion exchange resin is Purolite™ A194™ and A500™. The gold loading efficiency of these resins is not pH sensitive and they can operate effectively across the entire pH range. Medium base resins contain a mixture of tertiary, secondary, and primary amine groups. Commercial examples are Purolite™ S992™ and BASF™ Aurix™. Examples of other chelating resins include Purolite™ MTS8140™, MTS9200™, and MTS9240™ and DuPont™ AmberSep91419™, AmberSep 21KXLT™, and AmberLyst A21™. The sorbed precious metal can be eluted by any eluant suitable for the particular resin, such as a thiourea/sulfuric acid eluant, an isothiouronium eluant, a thiol resin, a polythionate eluant, an alkali such as sodium hydroxide, and the like.

Other previous metal recovery processes can be employed such as cementation (e.g., zinc or aluminum precipitation) and electrowinning.

EXPERIMENTAL

The following examples are provided to illustrate certain embodiments of the invention and are not to be construed as limitations on the invention, as set forth in the appended claims. All parts and percentages are by weight unless otherwise specified.

The catalyzed thiosulfate leach of gold from oxide ores was been evaluated. The pretreatment process of U.S. Pat. No. 10,161,016 was tested but it was sometimes difficult to reproduce results. Since a process that can increase the recovery of gold in thiosulfate leaching to such extent is promising, it was decided to further investigate it. Therefore, the objective was to understand the effect of activated carbon during the pretreatment and during the thiosulfate

leaching of gold, the causes behind the lack of reproducibility, and the mechanism by which a pretreatment with carbon could yield high gold recoveries from what otherwise would be considered as a thiosulfate-refractory ore. The experimental work determined that it is possible to increase gold recovery from certain ores without the need for ammonia or copper, and at low temperatures and atmospheric pressures, by adding small amounts of fine carbon during the thiosulfate leach of gold.

The addition of fine activated carbon resulted in increased dissolution rates and gold recoveries. It has been hypothesized that activated carbon and gold form a galvanic couple, and that oxygen reduction rate is increased due to the increased surface area available on activated carbon. The use of activated carbon as catalyst in the thiosulfate leach of gold is a process alternative that may not require the addition of surrogate oxidants (like copper) and that can work at lower temperatures, making it a more attractive option for the leaching of gold when cyanide use is not an option.

In a first series of experiments, three samples used were ground in a rod mill using tap water and at a pulp density of 60 wt. %. to a P₈₀ of 75 μm. The ground material was then homogenized and split into 200-g charges for leach test work. A 200-g charge was further split into 25-g charges for head assays. Solids were assayed for gold by fire assay followed by acid digestion and analyzed by AAS. Some samples were also analyzed for carbon speciation; total carbon was determined by LECO, organic carbon was also determined by LECO after inorganic carbon was removed by HCl digestion. Inorganic carbon was determined by the difference between total and organic carbon. Solutions were assayed for gold by AAS, for copper and other metals by ICP, and for thiosulfate and polythionates by ion chromatography.

Calcium thiosulfate resin-in-leach (RIL) experiments were performed in 1-L stainless steel stirred tanks. Unless otherwise specified, experimental conditions were: 50 degrees Celsius, pH 8 (adjusted and maintained with a 20 wt. % lime slurry), 0.1 M calcium thiosulfate (CaTS), 20 ppm Cu(II) (as CuSO₄.5H₂O), 0.5 L/min 0₂, 35 wt. % solids, 20 ml/L resin (Purolite A500™ (which is a macroporous polystyrene crosslinked with divinylbenzene)), and 24 hour residence time; agitation was set at 400 rpm. The activated carbon added to the leach experiments was ground using mortar and pestle; its particle size was not measured.

300 g of solids were slurried in DI water at the desired pulp density and heated to the target temperature in a water bath. After reaching the reaction temperature the resin was added to the reaction vessel, and then the calculated amounts of calcium thiosulfate and copper sulfate were added to the reactor. Finally, oxygen sparging was started, and this was considered as the beginning of the test. Slurry samples were generally collected at 1, 3, 6 and 24 hours. The resin in the samples was first screened and returned to the leach tank and the remaining slurry was filtered, and the solids thoroughly washed with DI water. The solids were dried in an oven at 50 degrees Celsius overnight, and then assayed for gold and, in some instances, for carbon speciation. The solutions were analyzed for gold and polythionates speciation. For the leach tests in the presence of activated carbon, the carbon was ground using mortar and pestle; its particle size was not measured.

The ore pretreatment conditions were 50 degrees Celsius, pH 8, 0.5 L/min 0₂, pH 8, 35 wt. % solids, 90 g of activated carbon per kg of ore, and 400 rpm. The duration of the pretreatment was six hours. Activated carbon was screened after the pretreatment, and the solids were re-slurried at the desired pulp density for the RIL experiment.

The gold grade in samples S1, S2 and S3 was 1.41, 2.54 and 3.63 g/ton, respectively. Organic carbon was only found in sample S3 (1.56 wt. %). The mineralogy of the three samples is shown in Table 1. Although samples S1 and S2 contained 1.6% pyrite, the leaching results suggest that most of the gold was exposed.

TABLE 1 Sample mineralogy. Ideal Chemical Mineral Formula Sample S1 Sample S2 Sample S3 Quartz SiO₂ 96.4 98.3 59.7 Jarosite KFe₃(SO₄)2(OH)₆ 1.9 Pyrite FeS₂ 1.9 1.7 Calcite CaCQ₃ 6.3 Dolomite CaMg(CO₃)₂ 20.8 Gypsum CaSO₄•2H₂O 4.9 Kaolinite Al₂Si₂O₅(OH)₄ 4.2 Micas Kal₂(AlSi₃O₁₀)(OH)₂ 4.1

FIG. 2 shows the effect of the carbon pretreatment on the dissolution of gold from sample S1. A cyanide leach test was also conducted for reference, and the recovery was 81.3%. The 24-h recovery of gold in the baseline thiosulfate RIL experiment was 26.2%. The cyanide and thiosulfate leach recoveries for sample S1 were 81.3 and 26.2%, respectively, indicating that the ore was refractory to thiosulfate leach; the possible causes for this refractoriness are thought to be related to the rate of oxygen reduction on the surface of gold. The results for two thiosulfate leach tests where the ore was pretreated according to the method of U.S. Pat. No. 10,161,016 are also shown in FIG. 2. Both pretreatments were conducted at the same conditions; both experiments increased both the dissolution rate of gold and its final recovery to 80.1-85.8% but the experiment was not reproducible. Nevertheless, the positive effect of the pretreatment on the thiosulfate leach of gold was clear. Based on these and previous observations, the objective of further experiments was to address two questions: first, how does the pretreatment with carbon affect the ore so that gold recovery by thiosulfate leach increases, and second, why was reproducibility not always achieved in these tests?

An important observation in these tests was that some trithionate (20-40 ppm) and tetrathionate (15-25 ppm) were observed throughout the thiosulfate leach tests in which the ore had been pretreated with carbon, but not in the baseline experiment. This observation led to the hypothesis that some activated carbon fines were deporting to the thiosulfate leach, and that this carbon was related to the increase in gold recovery. In fact, the residues of the leach tests where the feed was pretreated were assayed for organic carbon, and it was found that the content was 0.08 wt. % (no carbon was initially present in the sample).

To test this hypothesis, additional tests were performed where fine activated carbon (1-10 g/kg of ore) was added during the RIL leach. The effect of adding fine activated carbon (1-10 g/kg) to the CaTS-RIL tests is shown in FIG. 3. First, increasing the content of carbon from 1 to 5 g/kg resulted in an increase in the dissolution kinetics of gold, and increased gold recovery from 72.3 to 83.0%; a further increase in the content of carbon to 10 g/kg also resulted in an increase in recovery (84.4%) and slightly faster kinetics. Second, the addition of 1 g/kg of carbon produced a dissolution curve that was similar to that observed in the first carbon pretreatment experiment. Finally, the duplicate experiments at 5 g/kg carbon yielded reproducible results. These results support the hypothesis that fine activated carbon deporting to the RIL was the cause for the increased recoveries observed during RIL after the standard carbon pretreatment of the U.S. Pat. No. 10,161,016.

FIG. 4 shows gold dissolution curves for sample S2 in cyanide and thiosulfate leach experiments. NaCN concentration had to be increased from 0.2 to 2.0 g/L to increase gold recovery from 56.1 to 74.6%; although it is not shown in FIG. 4, the recovery for the 2 g/L NaCN test after 48 hours of leach was 82.0%. Gold dissolution from sample S2 was slower than from sample S1, regardless of the lixiviant used. The recovery of gold by thiosulfate leach in the absence of carbon was 15.4% but it is interesting to note that recovery increased for the first six hours of the test, where recovery was 26.4% but then dropped towards the end of the experiment. This experiment was repeated but the same behavior was observed. The results suggest that gold unloaded from the resin and then precipitated back to the solids. It should also be mentioned that no gold was detected in solution throughout this experiment. However, the addition of fine carbon to the thiosulfate leach experiments with sample S2 also increased gold recovery to 61.4 and 76.4% when fine carbon addition was 10 and 20 g/kg, respectively.

Lastly, FIG. 5 shows the effect of fine carbon on the gold recovery by thiosulfate from sample S3. Sample S3 was not refractory to thiosulfate as samples S1 and S2 were. The addition of fine carbon to this test did not affect gold recovery significantly; in fact, gold recovery decreased from 69.7 to 68.6% when carbon was added to the thiosulfate leach. For the purpose of this work, the main difference between sample S3 and samples S1 and S2 may be the carbon content in each ore (besides the differences in mineralogy). The content of organic carbon in sample S3 was 1.56 wt. % but no carbon was detected in neither sample S1 and S2. Thus, it is believed that the carbon present initially in sample S3 played a similar role to that of the addition of activated carbon. Since carbon was present in the baseline experiment, the addition of fine carbon was not expected to have a significant effect on gold recovery from sample S3.

The leach results observed with the three samples support the hypothesis that fine activated carbon deporting to the thiosulfate leach test was the cause for the increased recoveries observed after the standard carbon pretreatment disclosed in U.S. Pat. No. 10,161,016. The patent disclosed an increase in gold recovery from 60.7 to 71.1% when the duration of the pretreatment was extended from 6 to 24 hours; however, the patent did not disclose significant benefits when increasing the temperature or when using oxygen instead of air during the pretreatment. These teachings agree with the present results and can also be explained by the hypothesis that the carbon fines during the CaTS-RIL are responsible for the increases in gold recovery after the pretreatment. This is, increasing the duration of the pretreatment would increase carbon attrition, whereas the type of gas used, or temperature of the pretreatment would not. Differences in the amount of carbon deporting to the CaTS-RIL tests due to attrition during the carbon pretreatments can also help explain why it was difficult to achieve reproducibility in these experiments.

Up to this point, it can only be concluded that the presence of activated carbon during the thiosulfate leach increased gold recovery, and that reproducibility in the leach tests can be achieved by controlling the content of carbon in these experiments. The RIL experiments in the presence of activated carbon showed that carbon had a positive effect on gold recovery but they do not allow one to conclude about the effect of the carbon pretreatment on the recovery of gold by thiosulfate leaching. Although it is difficult (if not impossible) to prove that the pretreatment with carbon does not have an effect on gold recovery during RIL, unless carbon fines deport to the thiosulfate RIL, it was decided to conduct three different pretreatment experiments.

Preventing carbon attrition during the pretreatment of the ore was difficult, but it was decided to conduct two experiments using sample S1 to try to separate the effect of the pretreatment from the effect of carbon during thiosulfate leach. The first experiment consisted in pre-attriting activated carbon in an attempt to minimize the amount of fine carbon deporting to the RIL tests; the second experiment consisted in using a particular experimental setup. This setup consisted in a mesh pocket with activated carbon in it, that was immersed in a stirred tank containing a slurry with the sample to be pretreated; the slurry was also pumped through the mesh pocket to increase contact between carbon and the solids, while minimizing carbon attrition.

FIG. 6 shows the results for the pretreatments with pre-attrited carbon, and where carbon was placed in a mesh pocket. The recovery for the test where carbon was placed in the mesh pocket was the same as the baseline experiment; that is, the recovery for this test was similar to that observed without pretreatment. The recovery for the test using pre-attrited carbon in the pretreatment showed higher recoveries than the test with the first carbon pre-treatment. However, the RIL tails for the latter experiment were also assayed for carbon, and showed to contain 0.07 wt. % organic carbon. The differences in recovery between the pretreatments with the as-is carbon and with pre-attrited carbon seem to relate to the extent of carbon attrition during the pretreatment, and the amount of fines going to the RIL test. Unfortunately, the tails for the first carbon-pretreatment test were not assayed for carbon speciation.

After 24 hours, 5 g/t of fine carbon was added to the thiosulfate leach test, and resulted in an increase in gold dissolution rate and recovery.

The second experiment consisted in performing a carbon pretreatment on sample S1 followed by removal of the carbon from the solids by flotation prior to leaching with thiosulfate. After the flotation test, the grade of the flotation tails of the carbon pretreated sample was 0.55 g/t; the organic carbon content in the flotation tails was 0.06 wt. %. Other than the differences in ore-carbon contact configuration, the rest of conditions for the pretreatments were the same: 50 degrees Celsius, pH 8, 35 wt. % solids, 0.5 L/min 02, and six hours.

Two RIL tests were conducted on the flotation tails; a baseline experiment with no carbon added, and a RIL test in the presence of 10 g/kg fine carbon (see FIG. 7). The 24-h recovery of the baseline experiment was 3.6%, whereas the addition of fine carbon resulted in an increase in gold recovery to 63.6% after six hours of leaching. The results of these experiments suggest that the pretreatment with carbon as disclosed in U.S. Pat. No. 10,161,016 had no direct effect on thiosulfate leaching and that the fine carbon generated during the pretreatment caused the increased recoveries observed during the thiosulfate leach.

To explain the effect of carbon on the thiosulfate recovery of gold it is now hypothesized that carbon and gold form a galvanic couple where carbon acts as a cathode, thus providing an extended surface for the reduction of cupric ions or oxygen, and gold acts as anode and dissolves. Gold is the most noble metal under in the absence of lixiviants, However, in the presence of lixiviants the reduction potential of gold is affected, which allows gold dissolution to occur in aqueous solutions, at least from a thermodynamic perspective. The standard potentials for gold in water and in the presence of thiosulfate are listed in Table 2, all values are reported against the standard hydrogen electrode (SHE). Table 2 also includes the reduction potentials for gold and carbon at the thiosulfate leach conditions used in this work (50 degrees Celsius, pH 8, 0.1 M thiosulfate, 1.24×10-5 M CO₂, 5.08×10⁻⁸M Au(S₂O₃)₂ ³⁻).

TABLE 2 Standard reduction potentials for gold and carbon Standard Potential at Reaction Potential Leach Conditions Au^(•) + e⁻→ Au E⁰ = 1.83 V Not calculated 4H⁺ + CO₂ + 4e⁻→ C + 2H₂O E⁰ = −0.21 V E = 0.38 V Au(S₂O₃)₂ ³⁻ + e⁻ → Au + 2S₂O₃ ²⁻ E⁰ = −0.15 V E− = 0−.19− V−

In the thiosulfate system, the reduction potential of gold is lower than that of carbon by 192 mV; this means that if carbon and gold were to form galvanic couples, carbon would be cathodically protected by gold, and the dissolution of gold would probably be accelerated due to carbon acting as an extended surface for the electrochemical reduction of oxygen (see FIG. 8).

It is known that the dissolution rate of a gold electrode increases when connected to a pyrite electrode. It is further known that gold dissolution rates increase in leach experiments where gold was in the presence of pyrite. This has been attributed to o galvanic interactions between gold and different sulfides (pyrite, chalcopyrite, chalcocite and marcasite). It was reported that the dissolution rate of the gold electrode increased linearly with an increase in the area of the pyrite electrode, which is equivalent to what is observed in FIG. 9, which shows the final recoveries at different carbon concentrations for the results presented so far.

The effect of different variables on the robustness of the carbon catalyzed thiosulfate leaching of gold was evaluated. The objective of the following experiments was not to optimize the process but assess the sensitivity of the recovery to the concentrations of Cu(II) and thiosulfate, the addition of resin, and temperature.

FIG. 10 further shows the effect of Cu(II) on gold recovery by thiosulfate in the presence of 10 g/kg carbon. The dissolution curves with and without Cu(II) showed that there was no effect of cupric ions on final gold recovery or its dissolution kinetics. The reduction of oxygen on gold surfaces has been reported to be slow by different authors in ammonia-thiosulfate systems, and more recently in ammonia-free systems. To overcome this issue, cupric ions have been typically added in the ammonia-thiosulfate system to increase the dissolution of gold; this is possible because ammonia stabilizes the cupric ions as the Cu(NH3)i+ species, thus allowing Cu(II) to oxidize gold. In the absence of ammonia, the reduction of Cu(II) to Cu(I) is fast, which results in a lower solution Eh, which may be insufficient to drive the dissolution of gold at acceptable rates; this may help explain why the addition of cupric ions to the calcium thiosulfate system had no significant effect on either dissolution kinetics or final gold recovery.

Oxygen has been commonly added to the thiosulfate leach system to regenerate the cupric ions, but the addition of oxygen has also been reported to accelerate the degradation of thiosulfate in the presence of Cu(II) species to trithionate and tetrathionate, which is why the addition of oxygen and Eh of the system should be controlled carefully. It has further been reported that addition of 50 ppm Cu(II) to the sodium thiosulfate leach system did not affect gold recoveries, but increased the generation of trithionate and tetrathionate.

FIG. 10 also shows that removing the resin from the test had a detrimental effect on both the dissolution kinetics and final gold recovery. The recovery in the absence of resin was 78.7%, whereas in the presence of resin recovery was 82.3-85.1%. This could be attributed to the stability of the gold-thiosulfate complex, or to a decrease in the concentration gradient at the surface-solution interface which could affect the rate of dissolution of gold.

Decreasing temperature to 30 degrees Celsius (FIG. 10) resulted in slower dissolution kinetics but with a final recovery of 82.3%, which was close to that obtained at 50 degrees Celsius. Therefore, the addition of carbon to the thiosulfate leach system has also the potential to decrease energy requirements. Unfortunately, due to limitations in the amount of sample S1 available for this work, it was not possible to conduct tests at higher carbon dosages and lower temperatures.

FIG. 11 shows the effect of thiosulfate concentration on gold recovery from sample S1, in the presence and absence of 10 g/kg of carbon. In the absence of carbon, the initial dissolution rate of gold increased with increasing thiosulfate concentration; however, in all the tests in the absence of carbon gold recovery decreased with time after 3-6 hours of leach time. The reasons for this behavior were not understood, and it was not possible to continue the study. The addition of carbon helped to solve the problem, and much higher recoveries were observed in such

experiments (52 to 70%). However, it was interesting to note that the final recovery decreased with increasing thiosulfate concentration. It is believed that this behavior was specific to this sample and conclusions should not be extrapolated to the other samples tested in this work.

The above results (apart from the carbon pretreatment tests) correspond to tests performed in the presence of ground activated carbon. However, from a process point of view, this would mean that the added carbon would be lost to the leach tails. Therefore, it was decided to conduct a test where coarse carbon was added to the leach test so that it could be recovered afterwards. FIG. 12 shows a comparison of the experiment conducted with coarse activated carbon (70 g/kg) to tests performed with fine carbon at two different dosages (1 and 10 g/kg). The initial rate of dissolution in the presence of coarse carbon was lower than that observed in the experiments with fine carbon; this was expected, as the frequency of contact between coarse carbon and the gold surface would be lower than when fine carbon was used instead. However, the final recovery was 79.4%, which was higher than the recovery in the presence of 1 g/kg of fine carbon (72.3%) but lower than the test in the presence of 10 g/kg (84.4%). The amount of carbon in the tails was 0.11 wt. %, corresponding to losses of 1.1 g/kg (˜5% of carbon attrition). The economics of the process should be considered to decide whether the use of fine or coarse carbon is the best alternative.

The degradation of thiosulfate is an important factor from economic and chemical points of view. The generation of tetrathionate, particularly, has been associated to gold losses due to gold precipitation reactions. The main thiosulfate degradation products observed in this work were trithionate and tetrathionate but pentathionate and hexathionate were also observed in some instances, although they were not quantified. Thiosulfate consumption was lower than 2.11 g of thiosulfate per kg of ore, but there was no clear correlation between thiosulfate degradation and the operating conditions.

TABLE 3 Summary of gold recovery and thiosulfate consumption. S₂O₃ ²⁻ Test Temp. [S₂O₃ ²⁻] [Cu(ll)] [Resin] [C] Recovery consumption ID Ore ° C. M Mg/L cc/L g/kg % g/kg CaTS (1) S1 50 0.10 20 20 0 26.2 0.00 CaTS (2) S1 50 0.10 20 20 Pretreatment 80.1 0.06 CaTS (11) S1 50 0.10 20 20 Pretreatment 85.8 0.00 CaTS (3) S1 50 0.10 20 20 1 72.3 0.00 CaTS (4) S1 50 0.10 20 20 5 83.0 0.61 CaTS (13) S1 50 0.10 20 20 5 85.1 0.3.6 CaTS (8) S1 50 0.10 0 20 5 85.1 0.60 CaTS (9) S1 50 0.10 20 0 5 78.7 0.91 CaTS (10) S1 50 0.10 0 0 5 78.7 2.11 CaTS (5) S1 50 0.10 20 20 10 84.4 1.10 CaTS (12) S1 30 0.10 20 20 10 82.3 0.56 CaTS (17) S2 50 0.10 20 20 0 15.4 0.14 CaTS (18) S2 50 0.10 20 20 10 61.4 1.44 CaTS (24) S2 50 0.10 20 20 0 15.4 0.09 CaTS (27) S2 50 0.10 20 20 20 76.4 1.28 CaTS (28) S2 50 0.20 20 20 0 8.3 0.00 CaTS (29) S2 50 0.05 20 20 10 69.7 0.09 CaTS (30) S2 50 0.05 20 20 0 10.2 0.00 CaTS (31) S2 50 0.20 20 20 10 52.4 1.16 CaTS (32) S3 50 0.10 0 20 0 69.7 1.36 CaTS (33) S3 50 0.10 0 20 10 68.6 0.71

After it was confirmed that carbon fines were necessary to be present during the thiosulfate leaching of gold to catalyze the reaction, an experiment was performed to determine if carbon-solids contact was necessary to attain this effect. The experiment consisted in placing coarse activated carbon in a mesh pocket inside the RIL tank to minimize the contact between carbon and solids. FIG. 13 shows that gold recovery for this C-in-mesh experiment was very similar to that observed for the baseline experiment. FIG. 13 also shows that high dissolution rates and gold recoveries were obtained when temperature was decreased to 30° C., and also when neither copper sulfate or resin were added to the leach test.

Finally, FIG. 14 shows the effect of fine carbon on the thiosulfate leach of sample S2. Gold dissolution kinetics in sample S2 were slower than those observed with sample S1, both in the presence of cyanide and of thiosulfate. Compared to sample S1, sample S2 required longer residence times and higher NaCN concentrations to achieve complete recovery of the exposed gold. The baseline RIL thiosulfate experiment showed increasing gold recoveries for the first six hours; however, gold recovery dropped from 42.1 to 15.4% at the end of the experiment. The 15.4% recovery calculated from the tails assay agreed well with the recovery calculated from the gold assayed in the resin (16.1%). It has commonly been suggested that the reduction of oxygen is slow and that a catalyst is necessary to obtain acceptable kinetics. The results above show that in the presence of activated carbon, copper was not necessary to leach gold at acceptable leach rates.

The effect of activated carbon in the thiosulfate leaching of gold was evaluated. It was shown that fine activated increased gold recovery and its dissolution kinetics in the calcium thiosulfate leach system. It is believed that carbon and gold form a galvanic couple where the additional area provided by activated carbon increases the reduction of oxygen, thus increasing the electrochemical oxidation of gold. In the presence of fine carbon the addition of cupric ions had no effect on either gold recovery or its dissolution rate; it was also possible to decrease the leach temperature from 50 to 30 degrees Celsius and still obtain high gold recoveries. Coarse carbon could be used instead of fine carbon to decrease carbon losses to the tails, though process economics must be considered. Thiosulfate degradation was within 2.11 kg/ton, with trithionate and tetrathionate as the main degradation products.

The present results make the use of activated carbon as a catalyst in the thiosulfate leaching of gold an attractive process alternative in situations where cyanide use is not possible. This process, however, would be limited to stirred/fluidized reactors, and could not be applied to heap leaching.

A number of variations and modifications of the invention can be used. It would be possible to provide for some features of the invention without providing others.

For example in one alternative embodiment, the powdered activated carbon is added to a slurry comprising thiosulfate, the precious metal-bearing material and the oxidant during leaching of the precious metal.

In another alternative embodiment, the pretreatment process of U.S. Pat. No. 10,161,016 is first applied to the precious metal-bearing material, followed by carbon removal and addition of thiosulfate and finely sized carbon material. In the optional pre-treatment step (not shown in FIG. 1) performed before leaching is, the precious metal-bearing material is mixed with the carbon-based material and water to form a slurry and, after pre-treatment, the slurry is contacted with the thiosulfate lixiviant. Accordingly, the pre-treatment is commonly performed in the substantial absence of thiosulfate lixiviant. Typically, the pre-treatment slurry comprises no more than about 0.02 M, more typically no more than about 0.01 M, and even more typically no more than about 0.005 M thiosulfate. Proper reaction conditions during optional pre-treatment can provide relatively high leaching kinetics. Typically, the pre-treatment process is conducted at atmospheric pressure and temperature, though the use of a higher operating temperature (e.g., typically about 25° C. or higher, more typically about 35° C. or higher, and even more typically about 50° C. or higher and, in some applications typically in the range of from about 25° C. to about 65° C.) can provide improved reaction kinetics. The pH of the slurry is typically about pH 7 or higher, more typically about pH 8 or higher, and even more typically about pH 9 or higher. The oxidation-reduction potential (“ORP”) of the slurry is typically greater than about 100 mV and more typically greater than about 200 mV and typically less than about 750 mV and more typically less than about 500 mV (Ag/AgCl electrode). The rate of sparging of the oxidant (e.g., molecular oxygen) through the slurry during precious metal recovery typically ranges from about 0.05 to about 5 and more typically from about 0.10 to about 2.5 L O₂/L slurry/min. The residence time of the slurry in the mixing vessel typically ranges from more than about 1 hour to about 24 hours, depending on the temperature, dissolved oxygen concentration in solution, and the ore type. Typically, the pulp density ranges from about 20 to about 50% solids by weight, but could be as low as about 1% or as high as about 60%. The typical solids content of the slurry ranges from about 20 to about 30 wt. %. Ultimately, the treatment conditions, particularly time and temperature of the leaching process, carbon-based material dosage, and rate of oxygen addition, are adjusted to optimize precious metal recovery. This alternative may require less finely sized carbon to be consumed to realize a relatively high precious metal recovery.

In another embodiment, coarsely sized carbon-based material is added during the thiosulfate leach in addition to the ion exchange resin (which has a greater affinity for the dissolved precious metal than the carbon-based material) followed by carbon-based material removal, such as by screening, after the leach stage and before disposal of the residue to tailings. “Coarse” carbon-based material typically has a P₈₀ size of at least about 80 mesh sieve (0.177 mm) and more typically of at least about 50 mesh (0.297 mm). Typically, coarse carbon-based material includes, for example, granular activated carbon, extruded activated carbon, and bead activated carbon.

The present invention, in various embodiments, configurations, or aspects, includes components, methods, processes, systems and/or apparatus substantially as depicted and described herein, including various embodiments, configurations, aspects, subcombinations, and subsets thereof. Those of skill in the art will understand how to make and use the present invention after understanding the present disclosure. The present invention, in various embodiments, configurations, and aspects, includes providing devices and processes in the absence of items not depicted and/or described herein or in various embodiments, configurations, or aspects hereof, including in the absence of such items as may have been used in previous devices or processes, e.g., for improving performance, achieving ease and\or reducing cost of implementation.

The foregoing discussion of the invention has been presented for purposes of illustration and description. The foregoing is not intended to limit the invention to the form or forms disclosed herein. In the foregoing Detailed Description for example, various features of the invention are grouped together in one or more embodiments, configurations, or aspects for the purpose of streamlining the disclosure. The features of the embodiments, configurations, or aspects of the invention may be combined in alternate embodiments, configurations, or aspects other than those discussed above. This method of disclosure is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment, configuration, or aspect. Thus, the following claims are hereby incorporated into this Detailed Description, with each claim standing on its own as a separate preferred embodiment of the invention.

Moreover, though the description of the invention has included description of one or more embodiments, configurations, or aspects and certain variations and modifications, other variations, combinations, and modifications are within the scope of the invention, e.g., as may be within the skill and knowledge of those in the art, after understanding the present disclosure. It is intended to obtain rights which include alternative embodiments, configurations, or aspects to the extent permitted, including alternate, interchangeable and/or equivalent structures, functions, ranges or steps to those claimed, whether or not such alternate, interchangeable and/or equivalent structures, functions, ranges or steps are disclosed herein, and without intending to publicly dedicate any patentable subject matter. 

What is claimed is:
 1. A process, comprising: a) providing a particulate carbon-based material comprising one or more of activated carbon, activated charcoal, coke, hard carbon derived from at least one of coconut shells and elemental carbon, a calcined resin, and mixtures thereof; b) providing a precious metal-bearing material having a first precious metal thiosulfate leaching value in the absence of contact with the particulate carbon-based material; c) contacting the precious metal-bearing material with the particulate carbon-based material, thiosulfate, an anion exchange resin, and an oxidant to form a slurry; and d) leaching a precious metal from the slurried precious metal-bearing material, wherein the anion exchange resin has a greater affinity for the leached precious metal than the particulate carbon-based material and wherein the slurried precious metal-bearing material has a second precious metal thiosulfate leaching value that is more than the first precious metal thiosulfate leaching value.
 2. The process of claim 1, wherein the precious metal-bearing material is free of pretreatment by prior contact with the particulate carbon-based material and the oxidant.
 3. The process of claim 1, wherein the precious metal-bearing material is contacted with at least most of the thiosulfate lixiviant before contact with the oxidant, wherein the precious metal-bearing material contains more oxides than sulfides, wherein the precious metal-bearing material is substantially free of organic carbon before contact with the carbon-based material, and wherein the precious metal-bearing material is refractory to thiosulfate leaching.
 4. The process of claim 1, wherein the precious metal-bearing material is contacted with at least most of the ion exchange resin before contact with the oxidant, wherein the precious metal-bearing material is an oxide ore that is amenable to precious metal recovery by cyanidation, wherein the precious metal-bearing material has an average precious metal-bearing material particle size, wherein the particulate carbon has an average carbon particle size, and wherein the average carbon particle size is more than the average precious metal-bearing material particle size and further comprising: after the leaching step (d), removing the particulate carbon from the leached precious metal-bearing material by screening.
 5. The process of claim 1, wherein the oxidant is molecular oxygen, wherein, during the leaching step, the slurried precious metal-bearing material in step (d) has a pH of from about pH 7 to about pH 12, a thiosulfate concentrate of from about 0.005 to about 2 M, a total copper concentration of no more than about 20 ppm, and an oxidation-reduction potential ranging from about 100 to about 350 mV (vs the standard hydrogen electrode (SHE)), wherein a rate of contact of molecular oxygen with the slurry during step d) is at least 0.10 L O₂/L slurry/min, and wherein a weight ratio of the precious metal-bearing material to particulate carbon of more than about 100:1.
 6. The process of claim 1, wherein at least about 95% of the particulate carbon is removed from the slurried precious metal-bearing material after step (d).
 7. The process of claim 1, wherein the precious metal-bearing material is contacted with at least most of the thiosulfate before the precious metal-bearing material is contacted at least most of with the particulate carbon-based material and wherein the anion exchange resin comprises a strong-base or medium-base resin.
 8. The process of claim 1, wherein the precious metal-bearing material is contacted with at least most of the anion exchange resin before the precious metal-bearing material is contacted at least most of with the particulate carbon-based material and wherein the precious metal-bearing material comprises no more than about 0.01 wt. % organic carbon before contact with the carbon-based material.
 9. A process, comprising: a) contacting a gold-bearing material with a carbon-based material and one or more of a thiosulfate lixiviant and an anion exchange resin to form a slurry, the carbon-based material comprising one or more of activated carbon, activated charcoal, coke, hard carbon derived from at least one of coconut shells and elemental carbon, a calcined resin, and mixtures thereof; b) thereafter contacting the slurry with an oxidant to leach gold from the gold-bearing material and deposit the leached gold onto the anion exchange resin; and c) contacting the gold-containing anion exchange resin with an eluant to from a gold-containing eluant and a barren ion exchange resin for recycle to step (a).
 10. The process of claim 9, wherein the precious metal-bearing material is free of pretreatment by prior contact with the particulate carbon-based material and the oxidant, wherein the carbon-based material has an average carbon particle size and the gold-bearing material has an average gold-bearing material particle size, and wherein the average carbon particle size is more than the average gold-bearing material particle size, and further comprising after step (c) removing the carbon-based material from the leached gold-bearing material to form a carbon-depleted slurry, wherein the carbon-based material is removed by screening.
 11. The process of claim 9, wherein the precious metal-bearing material is contacted with at least most of the thiosulfate lixiviant before contact with the oxidant, wherein the gold-bearing material contains more oxides than sulfides, wherein the precious metal-bearing material is substantially free of organic carbon before contact with the carbon-based material, and wherein a gold recovery by thiosulfate leaching of the gold-bearing material in the absence of prior contact with the carbon is less than a gold recovery by thiosulfate leaching of the gold-bearing material after prior contact with the carbon.
 12. The process of claim 9, wherein the oxidant is molecular oxygen, wherein, during the thereafter contacting step, the slurry has a pH of from about pH 7 to about pH 12, a thiosulfate concentrate of from about 0.005 to about 2 M, a total copper concentration of no more than about 20 ppm, and an oxidation-reduction potential ranging from about 100 to about 350 mV (vs the standard hydrogen electrode (SHE)), wherein a rate of contact of molecular oxygen with the slurry during the thereafter contacting step is at least 0.10 L O₂/L slurry/min, wherein a weight ratio of the precious metal-bearing material to particulate carbon is more than about 100:1, wherein the precious metal-bearing material is contacted with at least most of the anion exchange resin before contact with the oxidant, wherein the gold-bearing material is an oxide ore that is amenable to gold recovery by cyanidation, and wherein at least part of the gold-bearing material is refractory to recovery of the gold by thiosulfate leaching.
 13. The process of claim 9, wherein the precious metal-bearing material is contacted with at least most of the thiosulfate before the precious metal-bearing material is contacted at least most of with the particulate carbon-based material and wherein the anion exchange resin comprises a strong-base or medium-base resin.
 14. The process of claim 10, wherein at least about 95% of the carbon is removed from the pre-treated slurry.
 15. The process of claim 8, wherein the precious metal-bearing material is contacted with at least most of the anion exchange resin before the precious metal-bearing material is contacted at least most of with the particulate carbon-based material and wherein the precious metal-bearing material comprises no more than about 0.01 wt. % organic carbon before contact with the carbon-based material.
 16. The process of claim 10, wherein, after step a), the pre-treated slurry comprises more than 0.005 molar thiosulfate.
 17. A process, comprising: a) contacting a precious metal-bearing material with a particulate carbon-based material, thiosulfate, and an anion exchange resin to form a slurry, wherein the precious metal-bearing material having a first precious metal thiosulfate leaching value in the absence of contact with the particulate carbon-based material and wherein the particulate carbon-based material comprising one or more of activated carbon, activated charcoal, coke, hard carbon derived from at least one of coconut shells and elemental carbon, a calcined resin, and mixtures thereof; and b) contacting the slurry with an oxidant to leach a precious metal from the slurried precious metal-bearing material, wherein the anion exchange resin has a greater affinity for the leached precious metal than the particulate carbon-based material and wherein the slurried precious metal-bearing material has a second precious metal thiosulfate leaching value that is more than the first precious metal thiosulfate leaching value.
 18. The process of claim 17, wherein the precious metal-bearing material is free of pretreatment by prior contact with the particulate carbon-based material and the oxidant.
 19. The process of claim 17, wherein the precious metal-bearing material is contacted with at least most of the thiosulfate lixiviant before contact with the oxidant, wherein the precious metal-bearing material contains more oxides than sulfides, wherein the precious metal-bearing material is substantially free of organic carbon before contact with the carbon-based material, and wherein the precious metal-bearing material is refractory to thiosulfate leaching.
 20. The process of claim 17, wherein the precious metal-bearing material is contacted with at least most of the ion exchange resin before contact with the oxidant, wherein the precious metal-bearing material is an oxide ore that is amenable to precious metal recovery by cyanidation, wherein the precious metal-bearing material has an average precious metal-bearing material particle size, wherein the particulate carbon has an average carbon particle size, and wherein the average carbon particle size is more than the average precious metal-bearing material particle size and further comprising: after step (b), removing at least about 95 wt. % of the particulate carbon from the leached precious metal-bearing material by screening.
 21. The process of claim 17, wherein the oxidant is molecular oxygen, wherein, during step (b), the slurried precious metal-bearing material has a pH of from about pH 7 to about pH 12, a thiosulfate concentrate of from about 0.005 to about 2 M, a total copper concentration of no more than about 20 ppm, and an oxidation-reduction potential ranging from about 100 to about 350 mV (vs the standard hydrogen electrode (SHE)), wherein a rate of contact of molecular oxygen with the slurry during step b) is at least 0.10 L O₂/L slurry/min, and wherein a weight ratio of the precious metal-bearing material to particulate carbon of more than about 100:1.
 22. The process of claim 17, wherein the precious metal-bearing material is contacted with at least most of the thiosulfate before the precious metal-bearing material is contacted at least most of with the particulate carbon-based material and wherein the anion exchange resin comprises a strong-base or medium-base resin.
 23. The process of claim 17, wherein the precious metal-bearing material is contacted with at least most of the anion exchange resin before the precious metal-bearing material is contacted at least most of with the particulate carbon-based material and wherein the precious metal-bearing material comprises no more than about 0.01 wt. % organic carbon before contact with the carbon-based material. 